Display device, and method and apparatus for manufacturing the same

ABSTRACT

A display device, and a method and apparatus for manufacturing the display device, are provided. The display device includes a cover window including a curved portion, and a display panel smaller in at least one of length or width than the cover window and laminated on a flat portion of the cover window.

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/235,023, filed Aug. 11, 2016, which is a continuation of U.S. patentapplication Ser. No. 13/871,970, filed Apr. 26, 2013, now U.S. Pat. No.9,439,315, which claims priority to and the benefit of Korean PatentApplication No. 10-2012-0071375, filed on Jun. 29, 2012 in the KoreanIntellectual Property Office, and of Korean Patent Application No.10-2013-0014650, filed on Feb. 8, 2013 in the Korean IntellectualProperty Office, the entire contents of all of which are incorporatedherein by reference.

BACKGROUND 1. Field

Aspects of embodiments of the present invention relate to a displaydevice, and a method and apparatus for manufacturing the display device.

2. Description of the Related Art

Electronic devices based on portability are widely used. Portableelectronic devices that have recently been widely used include smallelectronic devices such as mobile phones as well as tablet personalcomputers (PCs). In order to support various functions, portableelectronic devices include a display device for providing visualinformation such as an image to a user. Recently, as sizes of componentsfor driving display devices have decreased, the importance of displaydevices in electronic devices has increased. Accordingly, displaydevices (such as flexible display devices) that bend at a set angle (forexample, a predetermined angle) have been developed.

In general, flexible display devices that may bend at a set angle may bemanufactured using a flexible process, such as being flexiblymanufactured. Since a flexible display device may be formed of aflexible material, the flexible display device may have any of variousshapes. A flexible display device may be manufactured by forming alight-emitting unit on a substrate to form a display unit, and sealingthe display unit by using an encapsulation unit, which may increase alifetime of the display unit. The substrate may be formed of a flexiblematerial, and the encapsulation unit may be formed, for example, as asubstrate or a thin film. As designs of electronic devices have recentlybeen diversified, demands for flexible display devices have increased.

SUMMARY

Embodiments of the present invention provide for a display device havinga curved shape (for example, having an arc shape or a degree ofcurvature) that may enable efficient mass production, high reliability,and high quality. Further embodiments provide for a method and apparatusfor manufacturing the display device.

In an exemplary embodiment of the present invention, a display device isprovided. The display device includes a cover window including a curvedportion, and a display panel smaller in at least one of length or widththan the cover window and laminated on a flat portion of the coverwindow.

The display device may further include an adhesive layer between thedisplay panel and the cover window.

The cover window may further include a curved portion extending from theflat portion.

The display panel may be laminated entirely on the flat portion.

The curved portion may include a plurality of curved portions.

The display panel may include a first display panel portion laminated onthe flat portion, and a second display panel portion extending in acurved shape from the first display panel portion and laminated on thecurved portion.

The display panel may be flexible.

According to another exemplary embodiment of the present invention, amethod of manufacturing a display device is provided. The methodincludes: mounting a cover window including a curved portion to a firstjig including a curved portion; mounting a display panel, to which anadhesive layer is applied, to a second jig that conforms to a surface ofthe first jig; and laminating the cover window to the display panel bymoving one of the first jig or the second jig to another of the firstjig or the second jig.

The display panel may contact a flat surface of the second jig.

The display panel may be bent along an outer surface of the second jigduring the mounting of the display panel to the second jig.

The display panel may be smaller in at least one of length or width thanthe cover window.

The display panel and the adhesive layer may be flat during the mountingof the display panel to the second jig. The laminating of the coverwindow to the display panel may include partially curving the displaypanel and the adhesive layer by the moving of the one of the first jigor the second jig.

The one of the first jig or the second jig may be above the other of thefirst jig or the second jig, or the other of the first jig or the secondjig may be above the one of the first jig or the second jig.

The mounting of the display panel may include fixing the display panelto the second jig.

The display panel may be flexible.

According to yet another exemplary embodiment of the present invention,an apparatus for manufacturing a display device is provided. Theapparatus includes a first jig including a mount surface that ispartially curved to conform to a surface of a cover window, a second jigincluding a surface conforming to the mount surface and configured tocontact a display panel to which an adhesive layer is applied, and anactuator connected to one of the first jig or the second jig andconfigured to move the one of the first jig or the second jig.

The first jig may further include a first fixing unit for fixing thecover window to the mount surface, or the second jig may further includea second fixing unit for fixing the display panel to the surfaceconforming to the mount surface.

The first fixing unit or the second fixing unit may include anabsorption unit and a driving unit for evacuating air from theabsorption unit.

At least one of the first jig or the second jig may further include acushion unit at an outer surface of the at least one of the first jig orthe second jig.

The cushion unit may include a plurality of cushion units at respectiveends of the second jig. A distance between the cushion units may be lessthan at least one of length or width of the display panel.

The apparatus may further include a clamping unit spaced from the secondjig and configured to support the display panel to which the adhesivelayer is applied.

The clamping unit may include a plurality of clamping units. A distancebetween the clamping units may be less than at least one of length orwidth of the display panel when the clamping units support the displaypanel.

The apparatus may further include a driving unit coupled to the clampingunit and configured to linearly move the clamping unit.

The driving unit may be further configured to linearly move the clampingunit in a vertical direction of the second jig.

The driving unit may be further configured to linearly move the clampingunit in a diagonal direction of the second jig.

At least one of the first jig or the second jig may further include acushion unit at an outer surface of the at least one of the first jig orthe second jig.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other features and aspects of the present invention willbecome more apparent by describing in detail exemplary embodimentsthereof with reference to the attached drawings in which:

FIG. 1 is a cross-sectional view illustrating a display device accordingto an embodiment of the present invention;

FIG. 2 is a cross-sectional view illustrating a display panel of thedisplay device of FIG. 1;

FIG. 3 is a cross-sectional view illustrating an apparatus formanufacturing the display device of FIG. 1 according to an embodiment ofthe present invention;

FIGS. 4A through 4C are cross-sectional views illustrating a method ofmanufacturing the display device of FIG. 1 according to an embodiment ofthe present invention;

FIG. 5 is a cross-sectional view illustrating a display device accordingto another embodiment of the present invention;

FIG. 6 is a cross-sectional view illustrating an apparatus formanufacturing the display device of FIG. 5 according to an embodiment ofthe present invention;

FIGS. 7A through 7C are cross-sectional views illustrating a method ofmanufacturing the display device of FIG. 5 according to an embodiment ofthe present invention;

FIG. 8 is a cross-sectional view illustrating an apparatus formanufacturing the display device of FIG. 5 according to anotherembodiment of the present invention;

FIGS. 9A through 9C are cross-sectional views illustrating a method ofmanufacturing the display device of FIG. 5 according to anotherembodiment of the present invention;

FIG. 10 is a cross-sectional view illustrating an apparatus formanufacturing the display device of FIG. 5 according to yet anotherembodiment of the present invention;

FIG. 11 is a cross-sectional view illustrating a method of manufacturingthe display device of FIG. 5 according to yet another embodiment of thepresent invention;

FIG. 12 is a cross-sectional view illustrating an apparatus formanufacturing the display device of FIG. 5 according to still yetanother embodiment of the present invention; and

FIG. 13 is a cross-sectional view illustrating a method of manufacturingthe display device of FIG. 5 according to still yet another embodimentof the present invention.

DETAILED DESCRIPTION

Hereinafter, the present invention will be described more fully withreference to the accompanying drawings, in which exemplary embodimentsare shown. The present invention may, however, be embodied in manydifferent forms and should not be construed as being limited to theembodiments set forth herein. These embodiments are provided to makethis disclosure more thorough, and to help convey concepts of theinvention to one of ordinary skill in the art. The terminology usedherein is for describing particular embodiments only and is not intendedto be limiting of the present invention.

As used herein, the term “and/or” includes any and all combinations ofone or more of the associated listed items. Expressions such as “atleast one of,” when preceding a list of elements, modify the entire listof elements and do not modify the individual elements of the list. Asused herein, the singular forms “a,” “an,” and “the” are intended toinclude the plural forms as well, unless the context clearly indicatesotherwise. It will be further understood that the terms “comprises,”“comprising,” “includes,” and/or “including,” when used herein, specifythe presence of stated features, integers, steps, operations, elements,and/or components, but do not preclude the presence or addition of oneor more other features, integers, steps, operations, elements,components, and/or groups thereof. It will be understood that, althoughthe terms first, second, third, etc., may be used herein to describevarious elements, these elements should not be limited by these terms.These terms are only used to distinguish one element from anotherelement.

In the embodiments of the present invention, examples of display devicesinclude various display devices. For example, examples of displaydevices include liquid crystal display devices and organiclight-emitting display devices. However, for convenience of explanation,it will be assumed that the display devices are organic light-emittingdisplay devices.

FIG. 1 is a cross-sectional view illustrating a display device 100according to an embodiment of the present invention. FIG. 2 is across-sectional view illustrating a display panel 130 of the displaydevice 100 of FIG. 1.

Referring to FIGS. 1 and 2, the display device 100 includes a coverwindow 110, the display panel 130, and an adhesive layer 120. In FIG. 1,the cover window 110 is partially curved. That is, the cover window 110has a flat portion (on which the display panel 130 is laminated, withthe adhesive layer 120 therebetween) and at least one end of the flatportion is curved (e.g., a curved portion). As shown in FIG. 1, bothends of the flat portion are curved. As depicted, the cover window 110includes a flat portion 111 and curved portions 112 that extend from theflat portion 111. The curved portions 112 are formed on both ends of theflat portion 111.

The display panel 130 may be flexible. As shown, the display panel 130is smaller than the cover window 110. For example, the display panel 130is shorter in at least one of length or width than the cover window 110(due to the inward curvature of the cover window 110). For convenienceof explanation it will be assumed that the display panel 130 is shorterin width than the cover window 110. For example, the display panel 130may be laminated entirely on the flat portion 111 (and not on any of thecurved portions 112). The display panel 130 includes a first substrate Sand a light-emitting unit.

The display panel 130 may include an encapsulation unit formed on thelight-emitting unit. The encapsulation unit may be formed as a thinfilm. In another embodiment, the encapsulation unit may include a secondsubstrate instead of or in addition to a thin film. For convenience ofexplanation, however, it will be assumed that the encapsulation unit isformed as a thin film. In one embodiment, the display panel 130 mayinclude a touch unit. The touch unit will be described below in furtherdetail.

In FIG. 2, the light-emitting unit is formed on the first substrate S.The light-emitting unit includes a thin film transistor (TFT, in thiscase a driving TFT), a passivation film 131 formed to cover the TFT, andan organic light-emitting device, such as an organic light emittingdiode (OLED) 138 formed on the passivation film 131. The first substrateS may be formed of a glass material, but the present invention is notlimited thereto and, in other embodiments, the first substrate S may beformed of a plastic material or a metal material such as steel usestainless (SUS, or stainless steel) or titanium (Ti). In anotherembodiment, the first substrate S may include polyimide (PI). Forconvenience of explanation, it will be assumed that the first substrateS is formed of PI.

A buffer layer 132 formed of an organic compound and/or an inorganiccompound such as SiOx (x≥1) or SiNx (x≥1) is formed on a top surface ofthe first substrate S. An active layer 133 having a set pattern (forexample, a predetermined pattern) is formed on the buffer layer 132, andthen is covered by a gate insulating layer 134. The active layer 133includes a source region 133 a and a drain region 133 c, and a channelregion 113 b located between the source region 133 a and the drainregion 133 c. The active layer 133 may be formed by forming an amorphoussilicon film on the buffer layer 132, crystallizing the amorphoussilicon film to form a polycrystalline silicon film, and patterning thepolycrystalline silicon film. The source and drain regions 133 a and 133c of the active layer 133 are doped with impurities according to a typeof the TFT such as a driving TFT (for example, driving TFT in FIG. 2) ora switching TFT.

A gate electrode 135 corresponding to the active layer 133 and aninterlayer insulating layer 136 covering the gate electrode 135 areformed on a top surface of the gate insulating layer 134. After contactholes (for example, via-hole H1) are formed in the interlayer insulatinglayer 136 and the gate insulating layer 134, a source electrode 137 aand a drain electrode 137 b are formed on the interlayer insulatinglayer 136 to respectively contact the source region 133 a and the drainregion 133 c.

In some embodiments, a reflective film is formed at the same time (forexample, in the same layer) as the source/drain electrodes 137 a and 137b are formed as described above. Accordingly, each of the source/drainelectrodes 137 a and 137 b may be formed of a material having highelectrical conductivity and having a thickness great enough to reflectlight. Each of the source/drain electrodes 137 a and 137 b may be formedof a metal material such as silver (Ag), magnesium (Mg), aluminum (Al),platinum (Pt), palladium (Pd), gold (Au), nickel (Ni), neodymium (Nd),iridium (Ir), chromium (Cr), lithium (Li), calcium (Ca), or a compoundor alloy thereof.

The passivation film 131 is formed on the TFT. Then a pixel electrode138 a of the OLED 138 is formed on the passivation film 131. The pixelelectrode 138 a contacts the drain electrode 137 b of the TFT through avia-hole H2 formed in the passivation film 131. The passivation film 131may be formed of an inorganic material and/or an organic material andhave a single-layer structure or a multi-layer structure. As shown inFIG. 2, the passivation film 131 is formed as a planarization filmhaving a flat top surface regardless of any roughness or irregularitiesof a bottom surface. The passivation film 131 may be formed of atransparent insulating material to achieve a resonance effect.

After the pixel electrode 138 a is formed on the passivation film 131, apixel-defining film 139 is formed of an organic material and/or aninorganic material to cover the pixel electrode 138 a and thepassivation film 131, and is opened to expose the pixel electrode 138 a.An organic light-emitting layer 138 b and a counter electrode 138 c areformed on at least the pixel electrode 138 a. The pixel electrode 138 afunctions as an anode and the counter electrode 138 c functions as acathode, or vice versa.

The pixel electrode 138 a may be formed of a material having a high workfunction, such as indium tin oxide (ITO), indium zinc oxide (IZO),In₂O₃, or ZnO. The counter electrode 138 c may be formed of a metalmaterial having a low work function such as Ag, Mg, Al, Pt, Pd, Au, Ni,Nd, Ir, Cr, Li, Ca, or a compound thereof. For example, the counterelectrode 138 c may be formed of Mg, Ag, or Al to have a small thicknessto function as a semi-transmissive reflective film. Accordingly, thecounter electrode 138 c may optically resonate to transmit light.

The pixel electrode 138 a and the counter electrode 138 c are insulatedfrom each other by the organic light-emitting layer 138 b, and applyvoltages of different polarities to the organic light-emitting layer 138b for the organic light-emitting layer 138 b to emit light. The organiclight-emitting layer 138 b may be formed of a low molecular weightorganic material or a high molecular weight organic material.

If the organic light-emitting layer 138 b is formed of a low molecularweight organic material, the light-emitting layer 138 b may have asingle-layer or multi-layer structure formed by stacking a holeinjection layer (HIL), a hole transport layer (HTL), an emission layer(EML), an electron transport layer (ETL), and an electron injectionlayer (EIL). Examples of the low molecular weight organic materialinclude copper phthalocyanine (CuPc),N,N′-Di(naphthalene-1-yl)-N,N′-diphenyl-benzidine (NPB), andtris-8-hydroxyquinoline and aluminum (Alq3). The low molecular weightorganic material is formed by using vacuum deposition. The HIL, the HTL,the ETL, and the EIL may be commonly applied to red, green, and bluepixels. Accordingly, in some embodiments, the common layers may coverall pixels, like the counter electrode 138 c.

If the organic light-emitting layer 138 b is formed of a high molecularweight organic material, the organic light-emitting layer 138 b may havea structure including an HTL and an EML. The HTL may be formed ofpoly(3,4-ethylenedioxythiophene) (PEDOT) and the EML may be formed of ahigh molecular weight organic material based on polyphenylene vinylene(PPV) or polyfluorene. The high molecular weight organic material may beformed by using screen printing or inkjet printing. The organiclight-emitting layer 138 b is not limited thereto, and various examplesmay be formed, applied, deposited, etc., as would be apparent to one ofordinary skill in the art.

The encapsulation unit may be formed as a thin film as described above.In further detail, the encapsulation unit may be formed by alternatelystacking at least one organic layer and at least one inorganic layer. Insome embodiments, a plurality of inorganic layers or a plurality oforganic layers may be provided.

The organic layer may be formed of a polymer, and may have asingle-layer structure or a multi-layer structure formed of one or moreselected from the group including polyethylene terephthalate, polyimide,polycarbonate, epoxy, polyethylene, and polyacrylate. In one embodiment,the organic layer may be formed of polyacrylate. In further detail, theorganic layer may be formed by polymerizing a monomer compositionincluding a diacrylate-based monomer and a triacrylate-based monomer. Amonoacrylate-based monomer may be further included in the monomercomposition. In one embodiment, a well-known photoinitiator such as TPOmay be further included in the monomer composition, but otherembodiments of the present embodiment are not necessarily limitedthereto.

The inorganic layer may have a single-layer structure or a multi-layerstructure including a metal oxide or a metal nitride. In further detail,the inorganic layer may include one or more selected from the groupincluding SiNx, Al₂O₃, SiO₂, and TiO₂. In one embodiment, an uppermostlayer of the encapsulation unit that is exposed to the outside may be aninorganic layer to reduce or prevent moisture from penetrating into theorganic light-emitting device.

The encapsulation unit may have at least one sandwich structure in whichat least one organic layer is inserted between at least two inorganiclayers. In another embodiment, the encapsulation unit may have at leastone sandwich structure in which at least one inorganic layer is insertedbetween at least two organic layers.

The encapsulation unit may include a first inorganic layer, a firstorganic layer, and a second inorganic layer that are sequentiallystacked on the display unit. In another embodiment, the encapsulationunit may include a first inorganic layer, a first organic layer, asecond inorganic layer, a second organic layer, and a third inorganiclayer that are sequentially stacked on the light-emitting unit. Inanother embodiment, the encapsulation unit may include a first inorganiclayer, a first organic layer, a second inorganic layer, a second organiclayer, a third inorganic layer, a third organic layer, and a fourthinorganic layer that are sequentially stacked on the light-emittingunit.

A halogenated metal layer including LiF may be further disposed betweenthe light-emitting unit and the first inorganic layer. The halogenatedmetal layer may reduce or prevent the light-emitting unit from beingdamaged when the first inorganic layer is formed by using sputtering orplasma deposition.

The first organic layer may have an area smaller than that of the secondinorganic layer, and the second organic layer may have an area smallerthan that of the third inorganic layer. In one embodiment, the firstorganic layer may be completely covered by the second inorganic layer,and the second organic layer may be completely covered by the thirdinorganic layer.

The encapsulation unit may include a second substrate as describedabove. The second substrate may be formed similarly to the firstsubstrate S. For example, the second substrate may be formed of a glassmaterial, but like the first substrate S, the present invention is notlimited thereto and, in other embodiments, the second substrate may beformed of a different material, such as a plastic material.

The display device 100 may include a touch unit formed on the displaypanel 130 as described above. The touch unit may be located between thedisplay panel 130 and the adhesive layer 120. In other embodiments, thetouch unit may be a panel positioned on the display panel 130. Forexample, the touch unit may be formed on the encapsulation unit. Inanother embodiment, the touch unit may be formed on the cover window 110to have a panel shape or to have a pattern. As a method of forming atouch unit is well known to one of ordinary skill in the art, a detailedexplanation thereof will not be given. In addition, for convenience ofexplanation, it will be assumed that a touch unit is not formed on thedisplay panel 130.

The display device 100 includes the adhesive layer 120 that is locatedbetween the display panel 130 and the cover window 110. The adhesivelayer 120 may be variously formed. For example, the adhesive layer 120may include an adhesive film such as an optical clear adhesive (OCA)film or an adhesive material.

The adhesive layer 120 may have the same size as the display panel 130.In other embodiments, the adhesive layer 120 may be smaller than thedisplay panel 130. The adhesive layer 120 is attached on one surface ofthe display panel 130 to laminate the display panel 130 to the coverwindow 110. For example, the adhesive layer 120 may be applied to thesecond substrate.

Accordingly, the display device 100 that is partially curved may beattached to various electronic devices, and may easily display imageshaving various shapes. A method of manufacturing the display device 100will now be described with reference to FIGS. 3 through 4C.

FIG. 3 is a cross-sectional view illustrating an apparatus 200 formanufacturing the display device 100 of FIG. 1 according to anembodiment of the present invention. FIGS. 4A through 4C arecross-sectional views illustrating a method of manufacturing the displaydevice 100 of FIG. 1 according to an embodiment of the presentinvention. The same elements as those in FIG. 1 are denoted by the samereference numerals.

Referring to FIGS. 3 through 4C, the apparatus 200 includes a first jig210 that is partially curved and has a mount surface 211 that conformsto one surface of the cover window 110. In FIGS. 3 through 4C, the firstjig 210 has a shape similar to that of the cover window 110. That is,the mount surface 211 of the first jig 210 is curved. In addition, themount surface 211 has a flat portion on which the flat portion 111 ofthe cover window is mounted and the mount surface 211 has curvedportions on which the curved portions 112 of the cover window aremounted. For example, the mount surface 211 may be formed by beingrecessed in the first jig 210.

The apparatus 200 includes a second jig 220 that detachably couples tothe first jig 210. One surface of the second jig 220 conforms to themount surface 211. In FIGS. 3 through 4C, one surface of the second jig220 is curved to conform to the mount surface 211 that is curved. Thatis, the second jig 220 is curved such that the second jig 220 protrudestoward the first jig 210. The display panel 130 is mounted on the flatsurface of the second jig 220.

The apparatus 200 may include an actuator (such as second actuator 225)that is connected to at least one of the first jig 210 or the second jig220, and that moves the corresponding at least one of the first jig 210or the second jig 220. The actuator may include a first actuator thatmoves the first jig 210 and the second actuator 225 that moves thesecond jig 220. The first actuator and the second actuator 225 may beformed similarly. For convenience of explanation, it will be assumedthat the second actuator 225 is provided.

The second actuator 225 may include any of various devices. For example,the second actuator 225 may include a cylinder that operates by airpressure or oil pressure to move the second jig 220. In otherembodiments, the second actuator 225 may include a motor that operatesby electricity to move the second jig 220. For convenience ofexplanation, it will be assumed that the second actuator 225 includes acylinder.

The apparatus 200 includes a fixing unit (for example, second fixingunit 240) that prevents or helps prevent the cover window 110 mounted onthe first jig 210 from moving, or the display panel 130 and the adhesivelayer 120 mounted on the second jig 220 from separating from the secondjig 220. The fixing unit includes an absorption unit (for example,second absorption unit 241) that is formed on at least one of the firstjig 210 or the second jig 220. In addition, the fixing unit includes adriving unit (for example, second driving unit 242) that absorbs (forexample, vacuums or evacuates) air from the absorption unit. The fixingunit is not limited thereto and, in other embodiments, may be formed inother various ways as would be apparent to one of ordinary skill in theart. For example, the fixing unit may be a separate frame that is formedon the first jig 210 or the second jig 220. As another example, thefixing unit may be an adhesive member having an adhesive force.

The fixing unit may include a first fixing unit that is provided on thefirst jig 210, and includes a second fixing unit 240 that is provided onthe second jig 220. The first fixing unit and the second fixing unit 240may be formed similarly. For example, the first fixing unit and thesecond fixing unit 240 may fix the cover window 110 and the displaypanel 130 by using air. In other embodiments, the first fixing unit andthe second fixing unit 240 may fix the cover window 110 and the displaypanel 130 by using a separate frame. However, for convenience ofexplanation, it will be assumed that only the second fixing unit 240 isused and the display panel 130 is fixed by using air.

Accordingly, the apparatus 200 may rapidly and easily manufacture thedisplay device 100 having a curved shape and a simple structure. Inaddition, since the apparatus 200 may accurately laminate the coverwindow 110 having a curved shape to the display panel 130, a defect ratemay be reduced or minimized. A method of manufacturing the displaydevice 100 by using the apparatus 200 will now be described withreference to FIGS. 4A through 4C.

In order to manufacture the display device 100, the cover window 110 isfirst fabricated. The cover window 110 may include any of variousmaterials. For example, the cover window 110 may be formed of a glassmaterial or a plastic material. The cover window 110 is not limitedthereto and, in other embodiments, may include any material as long asthe cover window 110 is partially curved or capable of being partiallycurved.

After the cover window 110 is fabricated, it may be flat, in which casethe curved portions 112 may be formed by bending both ends of the coverwindow 110. For example, the curved portions 112 may be bent from theflat portion 111. In FIGS. 4A and 4C, the curved portions 112 extendfrom the flat portion 111 as described above, and each has an arc shapehaving a set radius (for example, a predetermined radius) or degree ofcurvature. In other embodiments, each of the curved portions 112 mayhave, for example, an oval shape instead of the arc shape.

The display panel 130 may be manufactured before, during, or after thecover window 110 is manufactured. A method of manufacturing the displaypanel 130 may be substantially the same as a method of manufacturing ageneral display panel (as would be apparent to one of ordinary skill inthe art) and thus, a further detailed explanation thereof will not begiven.

Once the display panel 130 is prepared, the adhesive layer 120 isattached on one surface of the display panel 130. For example, theadhesive layer 120 may be attached on the second substrate (or otherencapsulation unit) as described above. The adhesive layer 120 may, forexample, be attached as a film to the second substrate, or be applied asa material to the second substrate. However, for convenience ofexplanation, it will be assumed that the adhesive layer 120 is formed asa film.

After the adhesive layer 120 is attached to the display panel 130, thecover window 110 and the display panel 130 are respectively mounted onthe first jig 210 and the second jig 220. That is, the cover window 110is mounted on the first jig 210, and the display panel 130 is mounted onthe second jig 220. The first jig 210 may be below the second jig 220(for example, in a gravity direction).

Next, the distance between the first jig 210 and the second jig 220 isdecreased. For example, the first jig 210 may move toward the second jig220, or the second jig 220 may move toward the first jig 210. In otherembodiments, both the first jig 210 and the second jig 220 may movecloser to each other. However, for convenience of explanation, it willbe assumed that the second jig 220 moves.

One surface of the first jig 210 is curved to conform (for example,closely attach) to one surface of the cover window 110. In FIGS. 4A and4C, the surface of the first jig 210 is curved by being recessed. Inaddition, the display panel 130 is mounted on one surface of the secondjig 220. The second fixing unit 240 fixes the display panel 130 to thesurface of the second jig 220.

In FIGS. 4B and 4C, when the display panel 130 is mounted on the secondjig 220, a second absorption unit 241 contacts, adheres, or is otherwiseattached or fixed to one surface of the display panel 130. The secondabsorption unit 241 is partially exposed through an outer surface of thesecond jig 220. When the display panel 130 is positioned in this manner,the second driving unit 242 absorbs air from the second absorption unit241 (for example, by creating a partial vacuum or a pressuredifference). Since the display panel 130 closes (for example, occludes)all or a portion of the second absorption unit 241, and air in thesecond absorption unit 241 is continuously absorbed (for example,vacuumed or evacuated), the second absorption unit 241 is in an almostvacuum state. When the second driving unit 242 operates as describedabove, the display panel 130 attached to the second jig 220 is notseparated from the second jig 220 due to the pressure difference.

In FIGS. 3 through 4C, a plurality of second absorption units 241 isprovided. The second absorption units 241 are exposed or partiallyexposed through an outer surface of the second jig 220 as describedabove and are spaced apart from one another by a set interval (forexample, a predetermined interval, such as evenly spaced).

When the cover window 110, the adhesive layer 120, and the display panel130 are prepared as described above, the second jig 220 is moved towardthe first jig 210 by driving the second actuator 225. For example, thesecond actuator 225 may be programmed to operate for a set period oftime (for example, a predetermined period of time). When the secondactuator 225 operates in this manner, the second jig 220 approaches thefirst jig 210. When the second jig 220 is continuously moved toward thefirst jig 210, the adhesive layer 120 contacts the cover window 110.

In FIG. 4C, the adhesive layer 120 and the display panel 130 may be thesame size as the flat portion 111. Accordingly, when the second jig 220is moved toward the first jig 210, the adhesive layer 120 contacts onesurface of the flat portion 111. When the second actuator 225continuously operates, the adhesive layer 120 contacting the flatportion 111 is compressed against the flat portion 111. Thus, thedisplay panel 130 and the cover window 110 may be attached to each otherthrough lamination.

Accordingly, the method may rapidly and accurately manufacture thedisplay device 100 having a curved shape. Since the method accuratelylaminates the cover window 110 having a curved shape to the displaypanel 130, a defect rate may be reduced or minimized, and productquality may be improved.

FIG. 5 is a cross-sectional view illustrating a display device 300according to another embodiment of the present invention.

Referring to FIG. 5, the display device 300 includes a cover window 310,a display panel 330, and an adhesive layer 320. The cover window 310includes a flat portion 311 and curved portions 312. The cover window310 and the adhesive layer 320 are substantially the same as the coverwindow 110 and adhesive layer 120 of FIG. 1 and thus, a detailedexplanation thereof will not be repeated.

The display panel 330 includes a first display panel portion 331 that islaminated on the flat portion 311. In addition, the display panel 330includes second display panel portions 332 that extend from the firstdisplay panel portion 331 and are laminated or partially laminated onthe curved portions 312. The second display panel portions 332 extend ina curved shape from the first display panel portion 331. Accordingly,since the display device 300 includes the cover window 310 that iscurved and the display device 300 displays a flat portion and a curvedportion, a larger or maximum active area may be obtained. Further, dueto the inward curvature of the cover window 310, the display panel 330may be smaller in at least one of length or width than the cover window310. In addition, the display device 300 that is partially curved may beattached to various electronic devices, and may easily display imageshaving various shapes. For convenience of explanation, however, it willbe assumed that the display panel 330 is shorter in width than the coverwindow 310.

A method of manufacturing the display device 300 will now be describedwith reference to FIGS. 6 through 7C.

FIG. 6 is a cross-sectional view illustrating an apparatus 400 formanufacturing the display device 300 of FIG. 5 according to anembodiment of the present invention. FIGS. 7A through 7C arecross-sectional views illustrating a method of manufacturing the displaydevice 300 of FIG. 5 according to an embodiment of the presentinvention. The same members as those of FIG. 5 are denoted by the samereference numerals.

Referring to FIGS. 6 through 7C, the apparatus 400 includes a first jig410, a second jig 420, an actuator (such as first actuator 415), and afixing unit (for example, first fixing unit 430 and second fixing unit440). The first jig 410, the second jig 420, the actuator, and thefixing unit are similar to the first jig 210, the second jig 220, theactuator (for example, the second actuator 225), and the fixing unit(for example, second fixing unit 240), respectively, as described aboveand thus, a detailed explanation thereof will not be repeated.

The actuator may include the first actuator 415 and a second actuator,and the fixing unit includes the first fixing unit 430 and the secondfixing unit 440. The first actuator 415, the second actuator, the firstfixing unit 430, and the second fixing unit 440 are substantially thesame as the first actuator, the second actuator 225, the first fixingunit, and the second fixing unit 240, respectively, as described aboveand thus, a detailed explanation thereof will not be repeated. However,it will be assumed that the actuator including only the first actuator415 operates.

The apparatus 400 may include a cushion unit 490 provided on or a partof at least one of the first jig 410 or the second jig 420. In thisembodiment, a thickness of the cushion unit 490 may be greater than orequal to 0.5 mm and less than or equal to 3 mm. For convenience ofexplanation, however, it will be assumed that the cushion unit 490 ispart of a surface of the second jig 420. In FIGS. 6 through 7C, aplurality of cushion units 490 are part of respective end portions ofthe second jig 420 to face the first jig 410. The cushion units 490include a first cushion unit 491 and a second cushion unit 492 that arepart of a surface of the second jig 420 and spaced apart by a setinterval (for example, a predetermined interval) from each other. Thedistance between the first cushion unit 491 and the second cushion unit492 is less than at least one of length or width of the display panel330. For convenience of explanation, however, it will be assumed thatthe distance between the first cushion unit 491 and the second cushionunit 492 is less than a width of the display panel 330. The cushionunits 490 support the display panel 330 and help prevent air bubblesfrom being formed between the display panel 330 and the curved portions312 when the second jig 420 and the first jig 410 are compressed againsteach other with the display panel 330 and the cover unit therebetween.

Accordingly, the apparatus 400 may rapidly and easily manufacture thedisplay device 300 having a curved shape and a simple structure. Inaddition, since the apparatus 400 may accurately laminate the coverwindow 310 having a curved shape to the display panel 330, a defect ratemay be reduced or minimized. Further, since the apparatus 400 (such asthe second jig 420) includes the cushion unit 490, a defect rate thatmay increase during lamination of the display panel 330 to the coverwindow 310 on the curved portions 312 may be reduced.

A method of manufacturing the display device 300 will now be describedwith reference to FIGS. 6 through 7C.

A method of manufacturing the display device 300 by using the apparatus400 is similar to that described above. For example, the cover window310 and the display panel 330 may be manufactured as described above andmay be mounted on the first jig 410 and the second jig 420,respectively, (see FIG. 7A). Next, the first fixing unit 430 and thesecond fixing unit 440 respectively fix the cover window 310 and thedisplay panel 330 to the first jig 410 and the second jig 420. When afirst driving unit 432 operates, a first absorption unit 431 ismaintained in a vacuum (or near vacuum) state. Likewise, when a seconddriving unit 442 operates, a second absorption unit 441 is maintained ina vacuum (or near vacuum) state. Accordingly, the cover window 310 andthe display panel 330 are fixed to the first jig 410 and the second jig420, respectively.

In FIGS. 6 through 7C, the first jig 410 is higher than the second jig420 (for example, in a gravity direction). At least one of the first jig410 or the second jig 420 then moves towards the other. For example, thefirst jig 410 may move toward the second jig 420, or the second jig 420may move toward the first jig 410. In other embodiments, both the firstjig 410 and the second jig 420 move closer to each other. However, forconvenience of explanation, it will be assumed that the first jig 410moves toward the second jig 420. When the first jig 410 moves toward thesecond jig 420, the first actuator 415 operates. When the first actuator415 continuously operates, a curved surface of the cover window 310contacts the adhesive layer 320.

At first, the display panel 330 and the adhesive layer 320 may be flatagainst the second jig 420. Then, when the adhesive layer 320 and thecover window 310 contact each other, both ends of the display panel 330and the adhesive layer 320 may be curved (for example, through contactwith the cover window 310 that is curved). Next, a first display panelportion 331 (that is flat) and second display panel portions 332 (thatare curved) of the display panel 330 are formed. Accordingly, the firstdisplay panel portion 331 and the second display panel portions 332 areformed when the display panel 330 is adhered to the flat portion 311 andthe curved portions 312. The cover window 310 may be attached to thedisplay panel 330 through lamination as the first actuator 415 operatesas described above (see FIG. 7C). In other embodiments, the displaypanel 330 and the adhesive layer 320 may be bent along an outer surfaceof the second jig 420 when the display panel 330 and the adhesive layer320 are mounted on the second jig 420.

Accordingly, the method may rapidly and accurately manufacture thedisplay device 300 having a curved shape. Since the method accuratelylaminates the cover window 310 having a curved shape to the displaypanel 330, a defect rate may be reduced or minimized. In addition, sincethe method removes air bubbles that may be formed after the displaypanel 330 and the curved portions 312 are compressed, product qualitymay be improved.

FIG. 8 is a cross-sectional view illustrating an apparatus 500 formanufacturing the display device 300 of FIG. 5 according to anotherembodiment of the present invention. FIGS. 9A through 9C arecross-sectional views illustrating a method of manufacturing the displaydevice 300 of FIG. 5 according to another embodiment of the presentinvention.

Referring to FIGS. 8 through 9C, the apparatus 500 includes a first jig510, a second jig 520, an actuator (such as first actuator 515 andsecond actuator 525), and a fixing unit (for example, first fixing unit530). The first jig 510, the second jig 520, the actuator, and thefixing unit are substantially the same as those described above andthus, a detailed explanation thereof will not be repeated. The actuatormay include the first actuator 515 and the second actuator 525, and thefixing unit includes the first fixing unit 530 (including firstabsorption unit 531 and first driving unit 532). The first actuator 515,the second actuator 525, and the first fixing unit 530 are substantiallythe same as those described above and thus, a detailed explanationthereof will not be repeated.

The apparatus 500 includes a clamping unit 550 that is spaced apart by aset interval (for example, a predetermined interval) from the second jig520, and supports the display panel 330 to which the adhesive layer 320is applied. In other embodiments, the clamping unit 550 may be spacedapart by a set interval (for example, a predetermined interval) from thefirst jig 510, and supports the cover window 310. For convenience ofexplanation, however, it will be assumed that the clamping unit 550 isdisposed adjacent to the second jig 520.

The clamping unit 550 supports one or more ends of the display panel 330and the adhesive layer 320 when they are inserted into the clamping unit550. In FIGS. 8 through 9C, a plurality of clamping units 550 areprovided, where a distance between the clamping units 550 is less thanat least one of length or width of the display panel 330 when theclamping units 550 are fixing the display panel 330. Particularly, theclamping units 550 are placed at both ends of the cover window 310 inthe direction of the at least one of width or length of the cover window310. For convenience of explanation, however, it will be assumed that aplurality of clamping units 550 are provided, where a distance betweenthe clamping units 550 is less than width of the display panel 330 whenthe clamping units 550 are fixing the display panel 330 below in furtherdetail.

In FIGS. 8 through 9C, the clamping units 550 face respective sidesurfaces of the first jig 510, and fix respective ends of the displaypanel 330 and the adhesive layer 320. The clamping units 550 include afirst clamping unit 551 and a second clamping unit 552 that are spacedapart by a set interval (for example, a predetermined interval) fromeach other.

Accordingly, the apparatus 500 may rapidly and easily manufacture thedisplay device 300 having a curved shape and a simple structure. Inaddition, since the apparatus 500 may accurately laminate the coverwindow 310 having a curved shape to the display panel 330, a defect ratemay be reduced or minimized. Further, since the apparatus 500 includesthe clamping unit 550 to accurately align the display panel 330 and thecover window 310, working efficiency may be improved.

A method of manufacturing the display device 300 by using the apparatus500 will now be described with reference to FIGS. 9A through 9C.

First, the cover window 310 is formed, the display panel 330 is formed,and then the adhesive layer 320 is attached on the display panel 330.The cover window 310 may be mounted on the first jig 510 as describedabove (see FIG. 9A). Next, respective ends of the display panel 330 onwhich the adhesive layer 320 is attached are fixed to the first clampingunit 551 and the second clamping unit 552. For example, the respectiveends of the display panel 330 may be fixed by being inserted intoinsertion grooves formed in the first clamping unit 551 and the secondclamping unit 552.

Once the display panel 330 and the adhesive layer 320 are fixed in thismanner, middle portions of the display panel 330 and the adhesive layer320 are curved upward (for example, with respect to a gravitydirection). As shown in FIGS. 9B and 9C, since a distance between thefirst clamping unit 551 and the second clamping unit 552 is less than awidth of the display panel 330, the middle portions protrude toward thefirst jig 510. When the display panel 330 and the adhesive layer 320 arefixed, the display panel 330, the adhesive layer 320, and the coverwindow 310 may be compressed by moving at least one of the first jig 510or the second jig 520. For convenience of explanation, it will beassumed that the display panel 330, the adhesive layer 320, and thecover window 310 are compressed by moving both the first jig 510 and thesecond jig 520.

When the first jig 510 and the second jig 520 move, the first actuator515 and the second actuator 525 may operate to move the first jig 510and the second jig 520 closer to each other. The middle portions of thedisplay panel 330 and the adhesive layer 320 (which are curved downward)then contact the cover window 310. For example, the middle portions ofthe display panel 330 and the adhesive layer 320 may first contact aportion of the flat portion 311. When the first jig 510 and the secondjig 520 continuously move, the display panel 330 and the adhesive layer320 are adhered to the cover window 310 from the flat portion 311 as thefirst contacting portion to the curved portions 312. That is, thedisplay panel 330, the adhesive layer 320, and the cover window 310contact in an order from the flat portion 311 to the curved portions312.

At some point (for example, after the adhesive layer 320 contacts theflat portion 311), the second jig 520 may contact the display panel 330,the display panel 330 may detach from the clamping unit 550, and thefirst jig 510 and the second jig 520 may move closer to each other tofurther laminate the display panel 330 to the cover window 310.

Accordingly, the method may rapidly and accurately manufacture thedisplay device 300 having a curved shape. In addition, since the methodmay accurately laminate the cover window 310 having a curved shape tothe display panel 330, a defect rate may be reduced or minimized.Further, since the method removes air bubbles that may be formed afterthe display panel 330 and the curved portions 312 are compressed,product quality may be improved.

According to embodiments of the present invention, since a cover windowthat is partially curved and a display panel are rapidly and accuratelylaminated to each other, mass production, high reliability, and highquality may be achieved. In addition, since a display device may bemanufactured rapidly, manufacturing time and costs may be reduced.

FIG. 10 is a cross-sectional view illustrating an apparatus 600 formanufacturing the display device 300 of FIG. 5 according to yet anotherembodiment of the present invention. FIG. 11 is a cross-sectional viewillustrating a method of manufacturing the display device 300 of FIG. 5according to yet another embodiment of the present invention.

Referring to FIGS. 10 and 11, the apparatus 600 includes a first jig610, a second jig 620, an actuator (including first actuator 615 andsecond actuator 625), a clamping unit 650, and a fixing unit (forexample, first fixing unit 630). The first jig 610 and the second jig620 may be substantially the same as those described above and thus, adetailed explanation thereof will not be repeated.

The actuator may include the first actuator 615 and the second actuator625, and the fixing unit may include the first fixing unit 630. Thefirst actuator 615, the second actuator 625, and the first fixing unit630 may be substantially the same as those described above and thus, adetailed explanation thereof will not be repeated. The first fixing unit630 may include a first absorption unit 631 and a first driving unit632.

The clamping unit 650 may include a first clamping unit 651 and a secondclamping unit 652. The first clamping unit 651 and the second clampingunit 652 may be substantially the same as those described above andthus, a detailed explanation thereof will not be repeated.

The apparatus 600 may include a first linear driving unit 660 and asecond linear driving unit 670 which respectively vertically move thefirst clamping unit 651 and the second clamping unit 652 (for example,in a vertical direction with respect to gravity). The first lineardriving unit 660 and the second linear driving unit 670 may be formedsimilarly and thus, the following explanation will focus on the firstlinear driving unit 660.

The first linear driving unit 660 may include a first shaft 661 that isconnected to the first clamping unit 651 and linearly moves. In oneembodiment, the first linear driving unit 660 may include a firstdriving module 665 that drives the first shaft 661. The first drivingmodule 665 may include, for example, a cylinder or a motor. Forconvenience of explanation, however, it will be assumed that the firstdriving module 665 includes a motor. It will be further assumed that thefirst shaft 661 includes a ball screw that is lowered or raised as thefirst driving module 665 rotates.

The first linear driving unit 660 may include a first elastic unit 663that surrounds the first shaft 661. The first elastic unit 663 mayinclude a compression spring, and may be formed of an elastic materialsuch as rubber. For convenience of explanation, however, it will beassumed that the first elastic unit 663 includes a compression spring.The first elastic unit 663 may surround an outer surface of the firstshaft 661 as described above and thus may provide a restoring force tothe first clamping unit 651 when the first clamping unit 651 moves.

A method of manufacturing the display device 300 by using the apparatus600 will be described. The cover window 310 and the display panel 330may be formed, and then the adhesive layer 320 may be formed on thedisplay panel 330. Respective ends of the display panel 330 on which theadhesive layer 320 is formed may be fixed to the first clamping unit 651and the second clamping unit 652. Once the display panel 330 is fixed tothe first clamping unit 651 and the second clamping unit 652, middleportions of the display panel 330 and the adhesive layer 320 may becurved upward (for example, with respect to a gravity direction). Infurther detail, since an interval between the first clamping unit 651and the second clamping unit 652 is less than a width of the displaypanel 330, the middle portions may protrude toward the first jig 610.

After the display panel 330 and the adhesive layer 320 are disposed inthis manner, the display panel 330, the adhesive layer 320, and thecover window 310 may be compressed against one another by moving atleast one of the first jig 610 or the second jig 620. For convenience ofexplanation, however, it will be assumed that the display panel 330, theadhesive layer 320, and the cover window 310 are compressed by movingboth the first jig 610 and the second jig 620.

While the first jig 610 and the second jig 620 move in this manner, thefirst linear driving unit 660 and the second linear driving unit 670 mayoperate to vertically move the first clamping unit 651 and the secondclamping unit 652. The first clamping unit 651 and the second clampingunit 652 may move at a speed similar to a speed at which the second jig620 moves.

When the second jig 620, the first clamping unit 651, and the secondclamping unit 652 are raised in this manner, the display panel 330 andthe adhesive layer 320 may be raised while maintaining their curvedstates. When a distance between the first jig 610 and the second jig 620reaches a set distance (for example, a predetermined distance), thefirst clamping unit 651 and the second clamping unit 652 may releasefrom (for example, reduce their clamping force from) the display panel330 and the adhesive layer 320. During or after this releasing of thefirst clamping unit 651 and the second clamping unit 652, the firstlinear driving unit 660 and the second linear driving unit 670 may lowerthe first clamping unit 651 and the second clamping unit 652.

Next, the first actuator 615 and the second actuator 625 maycontinuously operate to bring the first jig 610 and the second jig 620closer (for example, adjacent) to each other (for example, the secondjig 520 may contact the display panel 330). As the first jig 610 and thesecond jig 620 move closer, the display panel 330, the adhesive layer320, and the cover window 310 may be compressed against one another. Amethod of compressing the display panel 330, the adhesive layer 320, andthe cover window 310 may be performed in the same manner as thatdescribed above and thus, a detailed explanation thereof will not berepeated.

Accordingly, the method may rapidly and accurately manufacture thedisplay device 300 having a curved shape. Further, the method may reduceor minimize a defect rate by accurately laminating the cover window 310having a curved shape to the display panel 330. In addition, the methodmay improve product quality by removing air bubbles that may begenerated after the display panel 330 and the curved portions 312 arecompressed.

FIG. 12 is a cross-sectional view illustrating an apparatus 700 formanufacturing the display device 300 of FIG. 5 according to still yetanother embodiment of the present invention. FIG. 13 is across-sectional view illustrating a method of manufacturing the displaydevice 300 of FIG. 5 according to still yet another embodiment of thepresent invention.

Referring to FIGS. 12 and 13, the apparatus 700 may include a first jig710, a second jig 720 (including a cushion unit 790), an actuator(including first actuator 715 and second actuator 725), a clamping unit750 (including a first clamping unit 751 and a second clamping unit752), a fixing unit (for example, first fixing unit 730), a first lineardriving unit 760, and a second linear driving unit 770. The first jig710 and the second jig 720 may be substantially the same as thosedescribed above and thus, a detailed explanation thereof will not berepeated.

The actuator may include the first actuator 715 and the second actuator725, and the fixing unit may include the first fixing unit 730. Thefirst actuator 715, the second actuator 725, and the first fixing unit730 (which includes first absorption unit 731 and first driving unit732) may be substantially the same as those described above and thus, adetailed explanation thereof will not be repeated.

The first linear driving unit 760 and the second linear driving unit 770may linearly move the first clamping unit 751 and the second clampingunit 752, respectively. The first linear driving unit 760 and the secondlinear driving unit 770 may linearly move the first clamping unit 751and the second clamping unit 752 in a diagonal direction, respectively,with respect to the second jig 720 (and, for example, with respect to agravity direction). Since the second linear driving unit 770 may beformed similarly to the first linear driving unit 760, the followingexplanation will focus on the first linear driving unit 760.

In further detail, the first linear driving unit 760 may include a firstshaft 761, a first driving module 765, and a first elastic unit 763. Thefirst shaft 761, the first driving module 765, and the first elasticunit 763 may be formed in a similar manner to that described above (suchas the first linear driving unit 660 in FIGS. 10-11) except that, thefirst shaft 761 is disposed in a diagonal direction to diagonally movethe first clamping unit 751 with respect to the second jig 720.

When the first linear driving unit 760 operates, the first drivingmodule 765 may vary a length of the first shaft 761. Since the firstdriving module 765 and the first shaft 761 are diagonally disposed withrespect to the second jig 720 as described above, the first clampingunit 751 may be diagonally moved by varying the movement of the firstshaft 761.

For example, when the first driving module 765 operates to diagonallymove the first shaft 761 downward with respect to the second jig 720,the first clamping unit 751 may diagonally move downward with respect tothe second jig 720 as the first shaft 761 moves. Likewise, when thefirst driving module 765 operates in an opposite direction to diagonallymove the first shaft 761 upward with respect to the second jig 720, thefirst clamping unit 751 may diagonally move upward with respect to thesecond jig 720 as the first shaft 761 moves. The first shaft 761 mayinclude a ball screw as described above and thus may rotate as the firstdriving module 765 operates. The first shaft 761 may diagonally movedownward or upward with respect to the second jig 720 as the firstdriving module 765 rotates.

The cushion unit 790 may be formed in various ways. For example, thecushion unit 790 may be part of an outer surface (e.g., a contactingsurface, such as a surface that contacts the cover window 310 or thedisplay panel 330) of at least one of the first jig 710 or the secondjig 720. In another embodiment, the cushion unit 790 may be part of aportion of such an outer surface of at least one of the first jig 710 orthe second jig 720. In another embodiment, the cushion unit 790 is partof the apparatus 700 and covers such an outer surface of at least one ofthe first jig 710 or the second jig 720. For ease of description, itwill be assumed that the cushion unit 790 is part of an entire suchouter surface of the second jig 720.

A method of manufacturing the display device 300 may be similar to thatdescribed above. In further detail, the display panel 330 and the coverwindow 310 may be prepared, and then the adhesive layer 320 may beapplied to the display panel 330. The display panel 330 to which theadhesive layer 320 is applied may be fixed by the first clamping unit751 and the second clamping unit 752. When the fixing is completed, thedisplay panel 330, the adhesive layer 320, and the cover window 310 maybe compressed against one another by moving at least one of the firstjig 710 or the second jig 720. A method of compressing the display panel330, the adhesive layer 320, and the cover window 310 may be similar tothat described above and thus, a detailed explanation thereof will notbe repeated.

When the first jig 710 and the second jig 720 move in this manner, thefirst clamping unit 751 and the second clamping unit 752 may also move.The first clamping unit 751 and the second clamping unit 752 may bediagonally moved by the first linear driving unit 760 and the secondlinear driving unit 770, respectively. The first clamping unit 751 andthe second clamping unit 752 may be raised diagonally with respect tothe second jig 720.

When the first clamping unit 751 and the second clamping unit 752 areraised and then an interval between the first jig 710 and the second jig720 reaches a preset interval, both ends of the display panel 330 may bereleased from the clamping unit 750. The display panel 330 may belaminated to the cover window 310 by the adhesive layer 320 beginningfrom a middle portion of the display panel 330.

During or after the releasing of the first clamping unit 751 and thesecond clamping unit 752 from the display panel 330, the first lineardriving unit 760 and the second linear driving unit 770 may operate tolower the first clamping unit 751 and the second clamping unit 752. Thefirst clamping unit 751 and the second clamping unit 752 may be lowereddiagonally with respect to the second jig 720. While the first clampingunit 751 and the second clamping unit 752 are lowered, the first jig 710and the second jig 720 may get closer to each other to compress thedisplay panel 330, the adhesive layer 320, and the cover window 310against one another. For example, the second jig 720 may contact thedisplay panel 330. A method of adhering the display panel 330 and thecover window 310 through compression may be similar to that describedabove.

When the display panel 330 and the cover window 310 are compressed byusing the first jig 710 and the second jig 720, the cushion unit 790 mayspread a force applied to the display panel 330 and the cover window310. In addition, the cushion unit 790 may help prevent the displaypanel 330 or the cover window 310 from being damaged by partiallyabsorbing a force applied to the display panel 330 and the cover window310.

Accordingly, the method may rapidly and accurately manufacture thedisplay device 300. Further, the method may reduce or minimize a defectrate by accurately laminating the cover window 310 having a curvedsurface to the display panel 330. In addition, the method may improveproduct quality by removing air bubbles that may be generated after thedisplay panel 330 and the curved portions 312 are compressed.

This application relates in general to a display device and moreparticularly, to a display device and a corresponding method andapparatus for manufacturing the display device that may rapidly,accurately, and cleanly manufacture the display device having a curvedshape. Small electronic devices having curved display devices havepresented challenges in accurately forming and aligning theircorresponding cover windows (for example, transparent protective covers)and display panels (such as OLED display panels or flexible OLED displaypanels), and adhering the cover windows to the display panels viatransparent adhesive without quality defects such as air bubbles betweenthe cover windows and the display panels.

Embodiments of the present invention address these problems by providinga display device having a curved cover window, a display panel that fitsin the cover window, and an adhesive layer between the display deviceand the cover window, together with an apparatus and method formanufacturing the display device. The cover window is fabricated with acurved shape (such as rounded edges) and mounted to a first jig having amount surface that conforms to the cover window. For example, the coverwindow may sit in the first jig (through gravity) or attach to the firstjig via a fixing unit, such as a vacuum suction device. Meanwhile, thedisplay panel (to which the adhesive layer is attached), is attached toa second jig by similar means. The distance between the jigs is thenclosed (by moving one or both jigs towards the other using, for example,actuators), allowing the display panel to press up to the cover windowand adhere via the adhesive layer, and without forming air bubblesbetween the cover window and the display panel.

In another embodiment, the display panel may be attached to a clampunit, such as a pair of clamps, and bent through a clamping force tomate cleanly with the cover window when the jigs are moved towards eachother. The clamps may be moved via dedicated driving units (for example,which drive ball screws through rotational movement to move the clamps)independently of the jigs, and may move, for example vertically ordiagonally with respect to the jigs (and with respect to a gravitydirection).

While the present invention has been particularly shown and describedwith reference to exemplary embodiments thereof, it will be understoodby those of ordinary skill in the art that various changes in form anddetails may be made therein without departing from the spirit and scopeof the present invention as defined by the following claims, andequivalents thereof.

What is claimed is:
 1. A display device comprising: a cover windowcomprising a curved portion and a flat portion; and a display panelcomprising: a substrate; a light-emitting unit on the substrate andcomprising an organic light emitting device; and a thin film on thelight-emitting unit, the thin film comprising an organic layer and aninorganic layer, wherein the display panel is smaller in at least one oflength or width than the cover window, is on the flat portion of thecover window, and defines: a first display panel portion on the flatportion; and a second display panel portion extending in a curved shapefrom the first display panel portion and on the curved portion.
 2. Thedisplay device of claim 1, further comprising an adhesive layer betweenthe first display panel portion and the cover window, and between thesecond display panel portion and the cover window.
 3. The display deviceof claim 1, wherein the display panel is flexible.
 4. The display deviceof claim 1, wherein the curved portion comprises a plurality of curvedportions.
 5. A display device comprising: a cover window comprising acurved portion and a flat portion; and a display panel comprising: asubstrate; a light-emitting unit on the substrate and comprising anorganic light emitting device; and a thin film on the light-emittingunit, the thin film comprising an organic layer and an inorganic layer,wherein the display panel is smaller in at least one of length or widththan the cover window and is entirely on the flat portion of the coverwindow.